Process intensification of the propane dehydrogenation considering coke formation, catalyst deactivation and regeneration—transient modelling and analysis of a heat-integrated membrane reactor

Abstract

A heat-integrated packed-bed membrane reactor is studied based on detailed, transient 2D models for coupling oxidative and thermal propane dehydrogenation in one apparatus. The reactor is structured in two telescoped reaction zones to figure out the potential of mass and heat integration between the exothermic oxidative propane dehydrogenation (ODH) in the shell side, including membrane-assisted oxygen dosing and the endothermic, high selective thermal propane dehydrogenation (TDH) in the inner core. The developing complex concentration, temperature and velocity fields are studied, taking into account simultaneous coke growth corresponding with a loss of catalyst activity. Furthermore, the catalyst regeneration was included in the simulation in order to perform an analysis of a periodic operating system of deactivation and regeneration periods. The coupling of the two reaction chambers in a new type of membrane reactor offers potential at oxygen shortage and significantly improves the achievable propene yield in comparison with fixed bed and well-established membrane reactors in the distributor configuration without inner mass and heat integration. The methods developed allow an overall process optimization with respect to maximum spacetime yield as a function of production and regeneration times.